Welded Metal Blank Cutting Sequence for Tolerance Control
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Solution Overview
Problem
The existing methods for producing press-formed welded metal parts are inefficient due to high dimensional tolerances in welded blanks, leading to significant scrap and increased production costs, as well as the complexity and expense of trimming operations.
Innovation Solution
A method involving the cutting of metal sheets with different properties, followed by welding and a subsequent cutting process using metal melting to create final welded metal blanks with reduced weld joints and improved dimensional accuracy, allowing for more efficient production and reduced scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high dimensional tolerances are used for welded blanks, then production cost is reduced, but scrap amount increases and material is wasted
Solution Approach 1:
The patent applies preliminary action by performing the cutting operation after welding instead of before. The welded blank is cut to final dimensions after the welding process, which allows the cutting tolerances to be applied to the final part rather than accumulating from individual sheet components. This sequence reversal reduces overall dimensional tolerance requirements and minimizes scrap material.
2Manufacturing precision
If high dimensional tolerances are used for welded blanks, then production cost is reduced, but trimming operation complexity increases
Solution Approach 1:
The patent performs the cutting operation as a preliminary action after welding but before final forming. By cutting the welded blank to near-final dimensions after welding, the subsequent trimming operation requires minimal material removal, significantly reducing trimming complexity and device requirements.
3Reliability
If tailored blanks are produced by joining metal sheets with different properties, then optimum material properties are achieved, but production cost increases
Solution Approach 1:
The patent performs the cutting operation after welding as a preliminary action that eliminates the need for expensive specialized nesting dies. By cutting to final dimensions after welding, standard cutting equipment can be used instead of custom tooling, significantly reducing manufacturing costs while maintaining the ability to join metal sheets with different properties.
Solution Approach 2:
The patent replaces expensive, specialized nesting dies with a more economical approach using standard cutting equipment. The cutting tool or die is used in its basic form after welding rather than requiring custom-designed, expensive tooling specific to each tailored blank configuration, reducing manufacturing cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs by minimizing scrap and the need for specialized dies, enhances flexibility in producing various parts, and improves the quality of press-formed welded parts by eliminating defects and achieving tighter tolerances.
Implementation Method 1
these two sheets are then joined through welding, for example using laser welding
Implementation Method 2
a subsequent cutting process using metal melting to create final welded metal blanks
Data Source
Figure 1A~1E
Figure 2~3
Figure 4~5
AI summary
The present application relates to a method of producing a welded metal blank (16), comprising the steps of : cutting a first initial metal sheet (1) and a second initial metal sheet (3) from a first (2) and second metal strip (4), joining the first and second initial metal sheets (1, 3) by welding so as to obtain an initial welded metal blank (9), the initial welded metal blank (9) comprising a weld joint (10) joining the first and the second initial metal sheets (1, 3), and cutting said initial welded metal blank (9) by a process involving metal melting so as to obtain at least one final welded metal blank (16) comprising a first metal blank portion (17) and a second metal blank portion (18) joined by a weld joint portion (19) consisting of a portion of the weld joint (10) obtained during the joining step.